Fitting Bulkhead

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SwampyWales

New Member
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4
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Wales
Hi

I have a Defender 90 which I removed the front bulkhead from to repair. I am now attempting to refit it!

Can anyone tell me how to do this!!! I cannot get the bulkhead in as the lugs on the "feet" catch the sills. I have measure these lugs and they are very, very similar in size to the original ones but for the life of me, I cannot get the bulkhead in.

It doesn't matter if I tilt it, or put it on straight, I cant get it past the sills.

Is there a trick to doing this? I really dont want to take the sills off - there must be a way?

Many thanks
 
SwampyWales said:
Hi

I have a Defender 90 which I removed the front bulkhead from to repair. I am now attempting to refit it!

Can anyone tell me how to do this!!! I cannot get the bulkhead in as the lugs on the "feet" catch the sills. I have measure these lugs and they are very, very similar in size to the original ones but for the life of me, I cannot get the bulkhead in.

It doesn't matter if I tilt it, or put it on straight, I cant get it past the sills.

Is there a trick to doing this? I really dont want to take the sills off - there must be a way?

Many thanks
Click to expand...
Could you clarify exactly what you mean by "front bulkhead"?
 
Turboman said:
Thanks. And by "sills", do you mean the little alloy strips that bolt along under the doors at the sides of the vehicle?
Click to expand...

Hopefully the attached image will explain. The red arrow shows where the bulkhead needs to go!!
 

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  • sills.JPG
    sills.JPG
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SwampyWales said:
Hopefully the attached image will explain. The red arrow shows where the bulkhead needs to go!!
Click to expand...
I am not absolutely certain, but it looks to me like you may have some kind of rock slider fitted, and there is certainly some chequer plate present.
But I can't see that either would interfere with the tube in the base of the door pillar going down into the gap.

Are you sure that everything is the same as when you removed it? I notice the outrigger looks very clean? Has that been replaced while the bulkhead has been out? Or have you replaced the bottom section of the door pillar on the bulkhead?
 
outrigger has been replaced yes.

it was a bugger to get the bulkhead out! Maybe I should have removed the sill to do that??? It is a simple job to remove the sills? Any advice gratefully received!
 
SwampyWales said:
outrigger has been replaced yes.

it was a bugger to get the bulkhead out! Maybe I should have removed the sill to do that??? It is a simple job to remove the sills? Any advice gratefully received!
Click to expand...
It is usual to remove the sills, then the bulkhead, and then replace the bulkhead, followed by the sills.
If the sills are standard, it is a simple unbolting job. But these vehicles have often been cut about quite a bit over the years.
If you have replaced the outrigger, it is unlikely to be in exactly the same place, and maybe not exactly the same size.
So probably best to take off the sills, and re-assemble in the usual way.
 
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